CN116024565A - Laser cladding repair equipment for gear tooth surface fatigue crack - Google Patents
Laser cladding repair equipment for gear tooth surface fatigue crack Download PDFInfo
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- 230000008439 repair process Effects 0.000 title claims abstract description 34
- 238000004372 laser cladding Methods 0.000 title claims abstract description 21
- 238000003466 welding Methods 0.000 claims abstract description 27
- 238000005253 cladding Methods 0.000 claims abstract description 21
- 238000012545 processing Methods 0.000 claims abstract description 8
- 238000007493 shaping process Methods 0.000 claims description 85
- 239000000843 powder Substances 0.000 claims description 33
- 230000003287 optical effect Effects 0.000 claims description 13
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- 230000008569 process Effects 0.000 claims description 7
- 229910052799 carbon Inorganic materials 0.000 claims description 6
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 3
- 229910000746 Structural steel Inorganic materials 0.000 claims description 3
- 229910045601 alloy Inorganic materials 0.000 claims description 3
- 239000000956 alloy Substances 0.000 claims description 3
- 239000013307 optical fiber Substances 0.000 claims description 2
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- 239000007788 liquid Substances 0.000 description 2
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- 238000005299 abrasion Methods 0.000 description 1
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- 230000005540 biological transmission Effects 0.000 description 1
- 238000007772 electroless plating Methods 0.000 description 1
- 238000009713 electroplating Methods 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 238000005461 lubrication Methods 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 230000009347 mechanical transmission Effects 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
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Abstract
The utility model relates to a gear tooth face fatigue crack's laser cladding repair equipment utilizes control system real-time detection fatigue crack's shape, has adopted different laser processing parameters respectively to the straightway of fatigue crack, curve section, especially to the curve section of fatigue crack with single laser beam replace two bundles of laser beams, has effectively guaranteed the welding quality of whole fatigue crack, and fatigue crack welding efficiency is high, cladding regional grain structure is even, has effectively improved the whole repair quality of fatigue crack.
Description
Technical Field
The invention belongs to the field of laser repair, and particularly relates to laser cladding repair equipment for gear tooth surface fatigue cracks.
Background
Gears are an important component of mechanical transmission systems that can fail and damage the gears during continuous operation at high speeds or under high load conditions. The failure and damage forms of the gears are determined by various factors such as lubrication conditions, working conditions, part materials, heat treatment means adopted in the manufacturing process, the manufacturing and mounting processes of the parts and the like. The failure of the gear can be generally divided into two major types, namely tooth damage and tooth surface damage, wherein the tooth damage is tooth breakage, and the tooth surface damage comprises four modes of plastic deformation, tooth surface gluing, abrasion and tooth surface fatigue of the tooth.
Tooth surface fatigue is a common situation of tooth surface damage, and because the equivalent stress to which the tooth surface of the gear is subjected is variable, when the bearing capacity to which the tooth surface is subjected is greater than the alternating equivalent stress to which the tooth surface material is subjected, fatigue cracks can be generated at the position for a long time. For some devices with precise structure and high manufacturing cost, direct replacement can cause great economic loss. For example, the production cost of high-precision gears, gears of generators and the like is high, the manufacturing cost is too high due to the fact that the failed gears are directly replaced, and the maintenance cost can be remarkably reduced due to the fact that repairing is selected. The repair process on the market generally comprises methods of spraying, electroplating, electroless plating, laser cladding and the like. As an emerging surface modification technology, laser cladding is most widely used in gear repair, and has the advantages of small heat affected zone, high metallurgical bonding degree and the like compared with the traditional repair means. Fatigue cracks, which occur based on tooth surfaces of gears in actual production, are generally irregularly shaped in the form of accompanying curves, corners, etc. In the cladding process, convection, heat transfer and mass transfer of the liquid in the molten pool are affected by a temperature field, so that solidification and component uniformity of the metal liquid in the molten pool are affected, and further, the surface quality of the cladding layer is decisively affected. However, in the prior art, no matched laser processing technology is formed for the shape of the fatigue crack, and only a single laser processing mode is generally adopted to be incident on the area to be repaired.
Because the actual fatigue crack is irregular, when laser is incident on the fatigue crack curve section, because the laser scanning speed of the curve or the corner is slower, if the laser processing technology which is the same as that of the straight line section is still adopted, the phenomena of over-burning of the welding seam, coarse grains and the like can be caused due to mismatching of the laser heat source and the scanning speed, so that the repair quality is improved by modulating proper laser spots, laser power and the like according to the actual fatigue crack shape, and the method is an important problem to be solved currently and urgently.
Disclosure of Invention
The invention relates to laser cladding repair equipment for gear tooth surface fatigue cracks, and aims to solve the problems of low repair quality caused by phenomena of overburning of laser cladding weld joints, coarse grains and the like of the gear tooth surface fatigue cracks in the prior art.
In order to achieve the above purpose, the invention adopts the following technical scheme:
a laser cladding repair device for gear tooth surface fatigue cracks is characterized in that: the fatigue crack is basically in a straight line section and a curve section, and the laser cladding repair equipment comprises:
the control system controls independent switches of the first wavelength laser and the second wavelength laser in the laser transmitter; the multifunctional mirror is arranged on the optical paths of the first wavelength laser and the second wavelength laser, a film layer is plated on the surface of the multifunctional mirror, the first wavelength laser passes through the multifunctional mirror and then vertically and downwards exits, the second wavelength laser passes through the multifunctional mirror and then is split into two split laser beams with the same energy, one split laser beam vertically and downwards exits through the multifunctional mirror, the other split laser beam vertically and downwards exits through the reflecting mirror, and the first split laser beam and the other split laser beam are arranged and distributed along the length direction of the fatigue crack; the powder feeding device also comprises a powder feeding channel which is obliquely arranged, wherein the powder feeding channel forms an included angle alpha with the vertical direction, and the powder feeding channel is pneumatic powder feeding.
Further, the first linear light shaping unit, the second linear light shaping unit and the third linear light shaping unit are respectively and independently arranged below the first wavelength laser beam, the one light splitting laser beam and the other light splitting laser beam, the first linear light shaping unit, the second linear light shaping unit and the third linear light shaping unit are connected to a displacement driving system, the displacement driving system is connected with the control system, and the displacement driving control system is used for controlling horizontal movement of the first linear light shaping unit, the second linear light shaping unit and the third linear light shaping unit.
Further, a repairing process of laser cladding repairing equipment for gear tooth surface fatigue cracks comprises the following steps of;
step 1), a control system obtains the curvature of a gear tooth surface fatigue crack to be repaired, and when the control system detects that the current shape of the fatigue crack is basically a straight line segment, a laser emitter emits a first wavelength laser beam, the laser power is 1800W-2100W, and the first wavelength laser beam is incident on the fatigue crack straight line segment;
step 2), detecting the curvature of the fatigue crack in real time by a control system, when the control system detects that the current shape of the fatigue crack is a curve segment, selecting a laser processing technology matched with the curvature of the current curve segment based on a database, closing a first wavelength laser beam by a laser emitter, and simultaneously emitting a second wavelength laser beam, wherein the second wavelength laser beam is split into a split laser beam and another split laser beam which are identical after passing through a multifunctional lens coated with a film layer, and the laser power of the split laser beam and the laser power of the other split laser beam are 1500-1700W, and the split laser beam and the other split laser beam are incident on the fatigue crack curve segment;
step 3), when the control system 2 detects that the current shape of the fatigue crack is restored to a basic straight line segment, the laser emitter turns off the second wavelength laser beam and simultaneously emits the first wavelength laser beam, the laser power is 1800-2100W, and the first wavelength laser beam is incident on the fatigue crack straight line segment;
the database in the step 2) realizes the integrated construction of welding process data through offline modeling in advance, and different curvatures of fatigue cracks correspond to different laser powers, laser spots, laser scanning speeds and powder feeding speeds.
Further, the laser transmitter is an optical fiber laser, the gear is made of 45 # carbon structural steel, and the material of the cladding layer alloy powder comprises C, cr, B, si, ni, fe, wherein the content of Fe is not less than 80%.
Further, in the step 1) and the step 3), the laser defocusing amount is 0 to-20 mm, the laser scanning speed is 300-600mm/min, the powder feeding speed is 30-50g/min, and the included angle alpha is 30-60 degrees.
In the step 2), the laser defocusing amount is 0 to-20 mm, the laser scanning speed is 240-480mm/min, the powder feeding speed is 24-40g/min, and the included angle alpha is 30-60 degrees.
Further, in step 1) and step 3), before the laser transmitter transmits the first wavelength laser beam, the control system controls the first linear light shaping unit to horizontally move out of the optical path; in the step 2), before the laser transmitter transmits the laser beam with the second wavelength, the control system controls the second linear light shaping unit and the third linear light shaping unit to horizontally move out of the light path; the light spot of the first wavelength laser in the step 1) and the step 3) incident on the fatigue crack straight line segment is a Gaussian laser light spot A, and the laser light spot A is circular and has a diameter of 2-3mm; the second wavelength laser in the step 2) is a Gaussian laser beam, the light spots of the split laser beam and the other split laser beam which are incident on the fatigue crack curve section are Gaussian laser light spots B, the shape of the laser light spots B is circular, and the diameter of the laser light spots B is 1.8-2.7mm.
According to another embodiment of the present invention, in step 1) and step 3), the control system controls the first linear light shaping unit to move horizontally out of the optical path before the laser transmitter emits the first wavelength laser beam; in the step 2), before the laser transmitter transmits the laser beam with the second wavelength, the control system controls the second linear light shaping unit and the third linear light shaping unit to horizontally move into the light path; the light spots of the first wavelength laser in the step 1) and the step 3) which are incident on the straight line section of the fatigue crack are Gaussian laser light spots, the laser light spot A is round, and the diameter is 2-3mm; the second wavelength laser in the step 2) is a Gaussian laser beam, the one split laser beam is modulated by a second linear light shaping unit to form a rectangular light spot C which is incident on the fatigue crack curve section, the other split laser beam is also modulated by a third linear light shaping unit to form a rectangular light spot C which is incident on the fatigue crack curve section, the width of the rectangular light spot C in the fatigue crack advancing direction is 1-2mm, and the length of the rectangular light spot C in the direction perpendicular to the fatigue crack advancing direction is 1.8-2.7mm.
According to another embodiment of the present invention, in step 1), step 3), the control system controls the first linear light shaping unit to move horizontally into the optical path before the laser transmitter emits the first wavelength laser beam; in the step 2), before the laser transmitter transmits the laser beam with the second wavelength, the control system controls the second linear light shaping unit and the third linear light shaping unit to horizontally move into the light path; the first wavelength laser beam in the step 1) and the step 3) is a Gaussian laser beam, the first wavelength laser beam is modulated into a rectangular light spot D which is incident on a fatigue crack straight line segment through a first linear light shaping unit, the width of the rectangular light spot D in the fatigue crack advancing direction is 1-2mm, and the length of the rectangular light spot D in the direction perpendicular to the advancing direction is 2-3mm; the second wavelength laser beam in the step 2) is a Gaussian laser beam, the one split laser beam is modulated into a rectangular light spot C which is incident on the fatigue crack curve section through a second linear light shaping unit, the other split laser beam is also modulated into a rectangular light spot C which is incident on the fatigue crack curve section through a third linear light shaping unit, the width of the rectangular light spot C in the fatigue crack advancing direction is 1-2mm, and the length of the rectangular light spot C in the direction perpendicular to the fatigue crack advancing direction is 1.8-2.7mm.
Advantageous effects
The utility model relates to a laser cladding repair equipment of gear tooth face fatigue crack utilizes control system real-time detection fatigue crack's shape, has plated the rete on the multifunctional lens, can the first wavelength laser beam of basic total transmission, half semi-transparent second wavelength laser beam has adopted different laser processing parameters respectively to fatigue crack's straightway, curve segment, has effectively guaranteed whole fatigue crack's welding quality, and welding efficiency is high, cladding regional grain structure is even, has effectively improved fatigue crack's whole repair quality.
Drawings
FIG. 1 is a schematic diagram of laser cladding repair equipment and gear tooth surface fatigue crack structure of the present application;
FIG. 2 is a schematic diagram of a circular Gaussian spot energy distribution;
FIG. 3 is a schematic diagram of a linear rectangular spot energy distribution;
FIG. 4 (a) is a schematic view of a first laser path of the present application; (b) is a schematic view of a second laser path of the present application; (c) is a schematic view of a third laser light path of the present application.
In the drawing the view of the figure,
1, a laser generator; 2, a control system; 3, a first wavelength laser beam; 4, a second wavelength laser beam; 5, a multifunctional lens; 6, a film layer; 7, a reflecting mirror; 8, splitting the laser beam; 9, another beam splitting laser beam; 10, a powder feeding channel; 11, a first linear light shaping unit; a second linear light shaping unit; 13, a third linear shaping unit; 14, fatigue crack of gear tooth surface.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. The components of the embodiments of the present invention generally described and illustrated in the figures herein may be arranged and designed in a wide variety of different configurations. Thus, the following detailed description of the embodiments of the invention, as presented in the figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of selected embodiments of the invention. All other embodiments, which can be made by a person skilled in the art without making any inventive effort, are intended to be within the scope of the present invention.
As an emerging surface modification technology, laser cladding is most widely used in gear repair, and has the advantages of small heat affected zone, high metallurgical bonding degree and the like compared with the traditional repair means. The quality of repairing fatigue cracks of the gear tooth surface depends on the welding quality of a cladding layer, and the welding quality of the cladding layer is influenced by a plurality of factors, so that the cladding layer with excellent welding performance can be obtained only when the parameters are matched with each other by considering various aspects such as cladding materials, laser power, laser spots, scanning speed, powder feeding speed and the like.
Example 1
Referring to fig. 1-4 (a), an embodiment of the present invention provides a laser cladding repair apparatus for fatigue crack of a gear tooth surface, the fatigue crack having a substantially straight line segment and a curved line segment, the laser cladding repair apparatus comprising:
a laser transmitter 1 and a control system 2, wherein the laser transmitter 1 transmits a first wavelength laser 3 and a second wavelength laser 4, and the control system 2 controls independent switches of the first wavelength laser 3 and the second wavelength laser 4 in the laser transmitter 1; the optical paths of the first wavelength laser 3 and the second wavelength laser 4 are provided with a multifunctional lens 5, the surfaces of the multifunctional lens 5 are plated with a film layer 6, the first wavelength laser 3 passes through the multifunctional lens 5 and then vertically and downwards exits, the second wavelength laser 4 passes through the multifunctional lens 5 and then is split into two identical laser beams, one split laser beam 8 passes through the multifunctional lens 5 and vertically and downwards exits, the other split laser beam 9 passes through a reflecting mirror 7 and then vertically and downwards exits, and the first split laser beam 8 and the other split laser beam 9 are arranged and distributed along the length direction of the fatigue crack; the powder feeding device also comprises a powder feeding channel 10 which is obliquely arranged, wherein the powder feeding channel 10 forms an included angle alpha with the vertical direction, and the powder feeding channel 10 is pneumatic powder feeding; the first linear light shaping unit 11, the second linear light shaping unit 12 and the third linear light shaping unit 13 are respectively and independently arranged below the vertically emergent first wavelength laser beam 3, the split laser beam 8 and the other split laser beam 9, and the first linear light shaping unit 11, the second linear light shaping unit 12 and the third linear light shaping unit 13 are connected to a displacement driving system (not shown) which is connected with the control system 2 and is used for controlling the horizontal movement of the first linear light shaping unit 11, the second linear light shaping unit 12 and the third linear light shaping unit 13.
In this embodiment, the surface of the multifunctional lens 5 is coated with a film layer 6, and when the laser transmitter 1 transmits the laser beam 3 with the first wavelength, the multifunctional lens 5 coated with the film layer 6 transmits substantially all of the laser beam, and the laser beam 3 with the first wavelength is emitted vertically downwards after passing through the multifunctional lens 5; when the laser transmitter 1 emits the second wavelength laser beam 4, the multifunctional lens 5 coated with the film layer 6 splits the second wavelength laser beam 4 into two identical split laser beams, one split laser beam 8 vertically and downwards emits through the multifunctional lens 5, the other split laser beam 9 vertically and downwards emits after passing through the reflecting mirror 7, and the split laser beam 8 and the other split laser beam 9 are arranged and distributed along the length direction of the fatigue crack;
further, in this embodiment, the first linear light shaping unit 11, the second linear light shaping unit 12, and the third linear light shaping unit 13 may move their positions according to actual situations, when a modulated linear rectangular light spot is required, the control system 2 is connected to a displacement driving system, the displacement driving system horizontally moves the first linear light shaping unit 11, the second linear light shaping unit 12, and the third linear light shaping unit 13 below the first wavelength laser beam 3, the split laser beam 8, and the other split laser beam 9, and the first linear light shaping unit 11, the second linear light shaping unit 12, and the third linear light shaping unit 13 may modulate a gaussian light spot into a rectangular light spot according to actual working conditions, see fig. 2 and 3; when the linear rectangular light spot does not need to be modulated, the displacement driving system horizontally moves the first linear light shaping unit 11, the second linear light shaping unit 12 and the third linear light shaping unit 13 out of the lower parts of the first wavelength laser 3, the split laser beam 8 and the other split laser beam 9.
According to another aspect of the present invention, there is provided a laser cladding repair process for gear tooth surface fatigue cracks, the repair process specifically comprising the steps of:
step 1), a control system 2 obtains the curvature of a gear tooth surface fatigue crack to be repaired, and when the control system detects that the current shape of the fatigue crack is basically a straight line segment, a laser transmitter 1 transmits a first wavelength laser beam 3, the laser power is 1800W-2100W, and the first wavelength laser beam 3 is incident on the straight line segment of the fatigue crack;
step 2), the control system 2 detects the curvature of the fatigue crack in real time, when the control system 2 detects that the current shape of the fatigue crack is a curve segment, a laser processing technology matched with the curvature of the current curve segment is selected based on a database, the laser transmitter 1 closes the first wavelength laser beam 3 and simultaneously transmits the second wavelength laser beam 4, the second wavelength laser beam 4 is split into a split laser beam 5 and another split laser beam 6 which are identical after passing through the multifunctional lens 5 coated with the film layer, the laser power of the split laser beam 5 and the other split laser beam 6 is 1500W-1700W, and the split laser beam 5 and the other split laser beam 6 are incident on the curve segment of the fatigue crack 14;
step 3), when the control system 2 detects that the current shape of the fatigue crack is restored to a basically straight line segment, the laser emitter 1 turns off the second wavelength laser beam 4 and simultaneously emits the first wavelength laser beam 3, the laser power is 1800W-2100W, and the first wavelength laser beam 3 is incident on the straight line segment of the fatigue crack.
The database in the step 2) realizes the integrated construction of welding process data through offline modeling in advance, and different curvatures of fatigue cracks correspond to different laser powers, laser spots, laser scanning speeds and powder feeding speeds.
In this embodiment, in step 2), when the detected fatigue crack is a curved line segment, if the scanning speed is too high, the welding path is shifted and the welding is dithered, so the laser scanning speed should be properly reduced at the curved line or the corner. When the laser scanning rate is reduced, if higher laser power is still adopted, the process parameters are not matched, so that phenomena such as overburning of a cladding welding line, coarse grains and the like are caused, and therefore, aiming at fatigue cracks of a curve section, the welding speed and the laser power are reduced, and a cladding layer with better welding quality can be theoretically obtained. On the other hand, in actual operation, if the welding speed and the laser power are reduced, the welding efficiency is reduced, and meanwhile, the slower laser scanning speed also affects the flow and uniformity of a molten pool, so that the welding efficiency of a curve section can be obviously improved by modulating two split laser beams, and the uniformity of the molten pool can be improved by simultaneously emitting the two split laser beams, thereby obtaining good welding quality.
Further, in this embodiment, the laser transmitter 1 is a multi-wavelength fiber laser, the gear material is 45 # carbon structural steel, and the cladding layer alloy powder contains C, cr, B, si, ni, fe, wherein the content of Fe is not less than 80%.
In the step 1) and the step 3), the laser defocusing amount is 0 to-20 mm, the scanning speed is 300 to 600mm/min, the powder feeding speed is 30 to 50g/min, the laser power is 1800W to 2100W, and the powder feeding inclination angle is 30 degrees to 60 degrees; in the step 2), the laser defocusing amount is 0 to-20 mm, the laser scanning speed is 240-480mm/min, the powder feeding speed is 24-40g/min, the laser power is 1500W-1700W, and the powder feeding inclination angle is 30-60 degrees.
Because the fatigue crack in the step 2) is curved, the laser scanning speed is reduced by 20%, and the corresponding powder feeding speed and laser power are synchronously reduced, so that a better cladding layer welding seam can be obtained.
Further, since the reflectivity of the metal material is high, the laser light may be set to a negative defocus amount in order to improve the laser light absorptivity.
Further, in order to avoid interference between the powder feeding channel and the laser incident light, the included angle alpha is set to be 30-60 degrees.
Further, in step 1), step 3), before the laser transmitter 1 emits the first wavelength laser beam 3, the control system 2 controls the first linear light shaping unit 11 to move horizontally out of the optical path;
in step 2), the control system 2 controls the second linear light shaping unit 12, the third linear light shaping unit 13 to move horizontally out of the optical path before the laser transmitter 1 emits the second wavelength laser beam 4;
the light spot of the first wavelength laser 3 in the step 1) and the step 3) incident on the fatigue crack straight line segment is a Gaussian laser light spot A, and the laser light spot A is round and has a diameter of 2-3mm; in the step 2), the second wavelength laser 4 is a gaussian laser beam, the light spots of the split one split laser beam 8 and the other split laser beam 9 incident on the fatigue crack curve section are gaussian laser light spots B, the laser light spots B are circular, and the diameter is 1.8-2.7mm.
In this embodiment, the two split laser beams in step 1), step 3) and step 2) are gaussian light spots, the gaussian light spots are generally commonly distributed with ellipsoidal heat sources, the heat sources are in the form of high middle energy and low edge energy, the energy is in gaussian distribution, and the gaussian light spots are relatively simple to form, see fig. 2. In the step 2), the heat accumulation effect of the fatigue crack curve section is more obvious, so that in order to make the grain structure at the boundary of the cladding weld more uniform, the diameter of the Gaussian laser spot in the step 2) is reduced by 10% compared with that of the Gaussian laser spot in the step 1), and the diameter is about 1.8-2.7mm.
Example two
Referring to fig. 4 (b), this embodiment is an improvement based on the first embodiment, and reference is made to the description of the first embodiment for the point where this embodiment is not concerned.
In this embodiment, in step 1) and step 3), before the laser transmitter 1 transmits the first wavelength laser beam 3, the control system 2 controls the first linear light shaping unit 11 to move horizontally out of the optical path;
in step 2), the control system 2 controls the second linear light shaping unit 12, the third linear light shaping unit 13 to move horizontally into the optical path before the laser transmitter 1 transmits the second wavelength laser beam 4;
the light spot of the first wavelength laser 3 in the step 1) and the step 3) incident on the straight line section of the fatigue crack is a Gaussian laser light spot, the laser light spot A is a circle, and the diameter is 2-3mm; in the step 2), the second wavelength laser 4 is a gaussian laser beam, the one split laser beam 8 is modulated by a second linear light shaping unit 12 into a rectangular light spot C incident on the fatigue crack curve segment, the other split laser beam 9 is also modulated by a third linear light shaping unit 13 into a rectangular light spot C incident on the fatigue crack curve segment, the width of the rectangular light spot C in the fatigue crack advancing direction is 1-2mm, and the length of the rectangular light spot C in the direction perpendicular to the fatigue crack advancing direction is 1.8-2.7mm.
In this embodiment, the first wavelength laser beam 3 in step 1) and step 3) is a gaussian laser spot a, the size of the gaussian laser spot is circular, the diameter is 2-3mm, laser shaping is simple, and the flatness of the cladding weld is good.
Because of the complexity of curved welding, the energy distribution to the laser is also higher in order to obtain better welding performance, so that linear light spots with uniformly distributed energy are adopted at the curve, and referring to fig. 3, the uniformity of the grain structure of the cladding layer of the fatigue crack curve section can be remarkably improved. The two parallel linear rectangular light spots can improve the fluidity and uniformity of a curve section molten pool, and the obtained cladding weld seam has higher grain structure uniformity and maintains welding efficiency. In addition, compared with the diameter of the laser spot A in the step 1), the length of the rectangular light spot C in the step 2) is reduced by 10%, and the properly reduced rectangular light spot can obviously reduce heat accumulation at the weld joint boundary, so that the welding quality is further improved.
Example III
Referring to fig. 4 (c), this embodiment is an improvement based on the first embodiment, and reference is made to the description of the first embodiment for the point where this embodiment is not concerned.
In step 1), step 3), the control system 2 controls the first linear light shaping unit 11 to move horizontally into the light path before the laser transmitter 1 transmits the first wavelength laser beam 3;
in step 2), the control system 2 controls the second linear light shaping unit 12, the third linear light shaping unit 13 to move horizontally into the optical path before the laser transmitter 1 transmits the second wavelength laser beam 4;
the first wavelength laser beam 3 in the step 1) and the step 3) is a gaussian laser beam, the first wavelength laser beam 3 is modulated by a first linear light shaping unit 11 into a rectangular light spot D incident on a straight line section of the fatigue crack, the width of the rectangular light spot D in the fatigue crack advancing direction is 1-2mm, and the length of the rectangular light spot D perpendicular to the advancing direction is 2-3mm; in the step 2), the second wavelength laser beam 4 is a gaussian laser beam, the one split laser beam 8 is modulated by a second linear light shaping unit 12 into a rectangular light spot C incident on the fatigue crack curve segment, the other split laser beam 9 is also modulated by a third linear light shaping unit 13 into a rectangular light spot C incident on the fatigue crack curve segment, the width of the rectangular light spot C in the fatigue crack advancing direction is 1-2mm, and the length of the rectangular light spot C in the direction perpendicular to the fatigue crack advancing direction is 1.8-2.7mm.
In this embodiment, the modulated first wavelength laser beam 3 in step 1) and the modulated first wavelength laser beam 8 in step 3) and modulated second wavelength laser beam 9 in step 2) are rectangular light spots, and the rectangular light spots are selected for the cladding path of the whole fatigue crack, so that the uniformity of the grain structure of the cladding weld seam can be greatly improved.
The width of the rectangular light spot D in the step 1) along the advancing direction of the welding seam is 1-2mm, the length of the rectangular light spot C in the advancing direction of the welding seam is 2-3mm, the width of the rectangular light spot C in the step 2) along the advancing direction of the fatigue crack is 1-2mm, and the length of the rectangular light spot C in the advancing direction of the fatigue crack is 1.8-2.7mm. This is because, since the effect of heat accumulation at the curved section is more pronounced, in order to make the grain structure more uniform at the weld boundary of the cladding, the length of the rectangular spot C in step 2) is reduced by 10% compared to the rectangular spot D in step 1), and the appropriately reduced rectangular spot can significantly reduce the heat accumulation at the weld boundary, thereby further improving the weld quality.
Claims (8)
1. A laser cladding repair device for gear tooth surface fatigue cracks is characterized in that: the fatigue crack is in a straight line section and a curve section, and the laser cladding repair equipment comprises:
the laser device comprises a laser transmitter (1) and a control system (2), wherein the laser transmitter (1) transmits a first wavelength laser beam (3) and a second wavelength laser beam (4), and the control system (2) controls independent switching of the first wavelength laser beam (3) and the second wavelength laser beam (4) in the laser transmitter (1); the multifunctional laser fatigue crack device is characterized in that a multifunctional lens (5) is arranged on the optical paths of the first wavelength laser beam (3) and the second wavelength laser beam (4), a film layer (6) is plated on the surface of the multifunctional lens (5), the first wavelength laser beam (3) vertically and downwards exits after penetrating through the multifunctional lens (5), the second wavelength laser beam (4) is split into two identical split laser beams after penetrating through the multifunctional lens (5), one split laser beam (8) vertically and downwards exits after penetrating through the multifunctional lens (5), the other split laser beam (9) vertically and downwards exits after penetrating through a reflecting mirror (7), and the one split laser beam (8) and the other split laser beam (9) are arranged and distributed along the length direction of the fatigue crack (14); the powder feeding device further comprises a powder feeding channel (10) which is obliquely arranged, wherein an included angle alpha is formed between the powder feeding channel (10) and the vertical direction, and the powder feeding channel (10) is pneumatic powder feeding.
2. The laser cladding repair apparatus for gear tooth face fatigue cracks according to claim 1, wherein: the device comprises a first wavelength laser beam (3) which is vertically emitted, a first beam-splitting laser beam (8) and another beam-splitting laser beam (9), wherein a first linear light shaping unit (11), a second linear light shaping unit (12) and a third linear light shaping unit (13) are respectively and independently arranged below the first wavelength laser beam, the first linear light shaping unit (11), the second linear light shaping unit (12) and the third linear light shaping unit (13) are connected to a displacement driving system, the displacement driving system is connected with a control system (2), and the displacement driving control system is used for controlling horizontal movement of the first linear light shaping unit (11), the second linear light shaping unit (12) and the third linear light shaping unit (13).
3. A repair process of a laser cladding repair apparatus for gear tooth surface fatigue crack according to claim 1 or 2, the repair process comprising the steps of;
step 1), a control system (2) obtains the curvature of a gear tooth surface fatigue crack (14) to be repaired, when the control system detects that the current shape of the fatigue crack is a straight line segment, a laser transmitter (1) transmits a first wavelength laser beam (3), the laser power is 1800-2100W, and the first wavelength laser beam (3) is incident on the fatigue crack straight line segment;
step 2), detecting the curvature of the fatigue crack in real time by a control system (2), when the control system (2) detects that the current shape of the fatigue crack is a curve segment, selecting a laser processing technology matched with the curvature of the current curve segment based on a database, closing a first wavelength laser beam (3) by a laser emitter (1) and emitting a second wavelength laser beam (4), and splitting the second wavelength laser beam (4) into a completely same one split laser beam (8) and another split laser beam (9) after passing through a multifunctional lens (5) coated with a film layer, wherein the laser power of the one split laser beam (8) and the other split laser beam (9) is 1500-1700W, and the one split laser beam (8) and the other split laser beam (9) are incident on the curve segment of the fatigue crack (14);
step 3), when the control system (2) detects that the current shape of the fatigue crack is restored to be a straight line segment, the laser transmitter (1) turns off the second wavelength laser beam (4) and transmits the first wavelength laser beam (3), the laser power is 1800-2100W, and the first wavelength laser beam (3) is incident on the fatigue crack (14) straight line segment;
the database in the step 2) realizes welding process data integration through offline modeling in advance, and different curvatures of fatigue cracks correspond to different laser powers, laser spots, laser scanning rates and powder feeding rates.
4. A repair process according to claim 3, wherein: the laser transmitter (1) is an optical fiber laser, the gear material is 45 # carbon structural steel, and the material of cladding layer alloy powder comprises C, cr, B, si, ni, fe, wherein the content of Fe is not less than 80%.
5. The repair process according to claim 3 or 4, wherein: in the step 1) and the step 3), the laser defocusing amount is 0 to-20 mm, the laser scanning speed is 300 to 600mm/min, the powder feeding speed is 30 to 50g/min, and the included angle alpha is 30 to 60 degrees;
in the step 2), the laser defocusing amount is 0 to-100 mm, the laser scanning speed is 240 to 480mm/min, the powder feeding speed is 24 to 40g/min, and the included angle alpha is 30 to 60 degrees.
6. The repair process according to claim 5, wherein: in the steps 1) and 3), before the laser transmitter (1) transmits the first wavelength laser beam (3), the control system (2) controls the first linear light shaping unit (11) to horizontally move out of the light path;
in the step 2), before the laser transmitter (1) emits the laser beam (4) with the second wavelength, the control system (2) controls the second linear light shaping unit (12) and the third linear light shaping unit (13) to horizontally move out of the light path;
the light spot of the first wavelength laser (3) in the step 1) and the step 3) incident on the fatigue crack straight line segment is a Gaussian laser light spot A, and the laser light spot A is round and has a diameter of 2-3mm; in the step 2), the second wavelength laser (4) is a Gaussian laser beam, the light spots of the split laser beam (8) and the other split laser beam (9) incident on the fatigue crack curve section are Gaussian laser light spots B, and the laser light spots B are circular in shape and have diameters of 1.8-2.7mm.
7. The repair process according to claim 5, wherein: in the steps 1) and 3), before the laser transmitter (1) transmits the first wavelength laser beam (3), the control system (2) controls the first linear light shaping unit (11) to horizontally move out of the light path;
in step 2), before the laser transmitter (1) emits the second wavelength laser beam (4), the control system (2) controls the second linear light shaping unit (12) and the third linear light shaping unit (13) to horizontally move into the optical path;
the light spot of the first wavelength laser (3) in the step 1) and the step 3) incident on the straight line section of the fatigue crack is a Gaussian laser light spot A, and the laser light spot A is circular and has a diameter of 2-3mm; in the step 2), the second wavelength laser (4) is a Gaussian laser beam, the one split laser beam (8) is modulated into a rectangular light spot C which is incident on the fatigue crack curve section through a second linear light shaping unit (12), the other split laser beam (9) is also modulated into a rectangular light spot C which is incident on the fatigue crack curve section through a third linear light shaping unit (13), the width of the rectangular light spot C in the fatigue crack advancing direction is 1-2mm, and the length of the rectangular light spot C in the direction perpendicular to the fatigue crack advancing direction is 1.8-2.7mm.
8. The repair process according to claim 5, wherein: in the steps 1) and 3), before the laser transmitter (1) transmits the first wavelength laser beam (3), the control system (2) controls the first linear light shaping unit (11) to horizontally move into the light path;
in step 2), before the laser transmitter (1) emits the second wavelength laser beam (4), the control system (2) controls the second linear light shaping unit (12) and the third linear light shaping unit (13) to horizontally move into the optical path;
the first wavelength laser beam (3) in the step 1) and the step 3) is a Gaussian laser beam, the first wavelength laser beam (3) is modulated into a rectangular light spot D which is incident on a straight line section of the fatigue crack through a first linear light shaping unit (11), the width of the rectangular light spot D in the fatigue crack advancing direction is 1-2mm, and the length of the rectangular light spot D in the direction perpendicular to the advancing direction is 2-3mm; in the step 2), the second wavelength laser beam (4) is a Gaussian laser beam, the one split laser beam (8) is modulated into a rectangular light spot C which is incident on the fatigue crack curve section through a second linear light shaping unit (12), the other split laser beam (9) is also modulated into a rectangular light spot C which is incident on the fatigue crack curve section through a third linear light shaping unit (13), the width of the rectangular light spot C in the fatigue crack advancing direction is 1-2mm, and the length of the rectangular light spot C in the direction perpendicular to the fatigue crack advancing direction is 1.8-2.7mm.
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